MANUAL - TorcUP · 2018. 5. 25. · 1. OPERATION AND MAINTENANCE. MODELS TX-1, TX-2, TX-4, TX-8, TX-16, TX-32, TX-45. MANUAL. TX Series Low Profile Hydraulic Torque Wrenches. TX Series.

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OPERATION AND MAINTENANCE

MODELS TX-1, TX-2, TX-4, TX-8, TX-16, TX-32, TX-45

MANUALTX Series Low Profile Hydraulic Torque Wrenches

TX Series

Phone: +1 610-250-5800 Fax: +1 610-250-2700

Toll Free: 1-888-TORCUP-1Email: [email protected] Website: www.torcup.com1025 Conroy Place, Easton PA 18040 U.S.A.

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Operational and Maintenance Manual for TorcUP TX-1, TX-2, TX-4, TX-8, TX-16, TX-32 and TX-45

Low Profile Hydraulic Torque WrenchesVersion 2: 2016 September

Series TX-1, TX-2, TX-4, TX-8, TX-16, TX-32 and TX-45 Low Profile Hydraulic Torque Wrenches are designed for installing and removing threaded fasteners having minimal wrench clearance and requiring

precise high torque during bolt makeup and maximum torque for bolt breakout.

TorcUP Inc. is not responsible for customer modification of tools for applications on which TorcUP Inc. was not consulted.

IMPORTANT SAFETY INFORMATION ENCLOSED.READ THIS MANUAL BEFORE OPERATING TOOL.

IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PLACE THE INFORMATION IN THIS MANUAL INTO THE HANDS OF THE OPERATOR.

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.

USING THE TOOL

• Always operate, inspect and maintain this tool in accordance with American National Standards Safety Code for Hydraulic Rams and Jacks (ANSI B30.1).

• This tool will function using an air or electric powered hydraulic pump. Adhere to the pump safety requirements and follow instructions when connecting the pump to the tool.

• Use only equipment rated for the same pressure and torque.• Use only a hydraulic pump capable of generating 10,000 psi (681 bar) maximum pressure with this

tool.• Use only twin line hydraulic hose rated for 10,000 psi (681 bar) pressure with this tool.• Do not interchange the male and female swivel inlets on the tool or the connections on one end of

the hose. Reversing the inlets will reverse the power stroke cycle and may damage the tool.• Do not use damaged, frayed or deteriorated hoses and fittings. Make certain there are no cracks,

splits or leaks in the hoses.• Use the quick connect system to attach the hoses to the tool and pump.• When connecting hoses that have not been preloaded with hydraulic oil, make certain the pump

reservoir is not drained of oil during start-up.• Do not remove any labels. Replace any damaged label.• Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing

serious injury. If oil is injected under the skin, see a doctor immediately.• Never pressurize uncoupled couplers. Only use hydraulic equipment in a coupled system.• Always wear eye protection when operating or performing maintenance on this tool.• Always wear head and hand protection and protective clothing when operating this tool.

NOTICE

WARNING

For Technical Support & Information Contact:TorcUP Inc.

1025 Conroy Place, Easton, PA 18040 USAPhone: +1 610-250-5800 Fax:+1 610-250-2700

email: [email protected]

The use of other than genuine TorcUP replacement parts may result in safety hazards, decreased tool performance, increased maintenance, and may invalidate

all warranties. Repairs should be made only by authorized personnel. Consult your nearest TorcUP Authorized Service Center.

Refer All Communications to the Nearest TorcUP Office or Distributor.

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FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY

Do NOT Exceed Maximum Pressure. See Torque Chart with Tool. Damage May Occur.

Always wear eyeprotection when operating orperforming maintenance on this tool.

Always wear ear protection when operating this tool.

Do not carry the toolby the hose.

Keep body stance balanced and firm. Do not overreachwhen operating this tool.

USING THE TOOL

• Keep hands, loose clothing and long hair away from the reaction arm and working area during operation. • This tool will exert a strong reaction force. Use proper mechanical support and correct reaction arm

positioning to control these forces. Do not position the reaction arm so that it tilts the tool off the axis of the bolt and never use the swivel inlets as a reaction stop.

• Avoid sharp bends and kinks that will cause severe back-up pressure in hoses and lead to premature hose failure.

• Use accessories recommended by TorcUP. • Use only impact sockets and accessories. Do not use hand (chrome) sockets or accessories.• Use only sockets and accessories that correctly fit the bolt or nut and function without tilting the tool off the

axis of the bolt.• This tool is not insulated against electric shock. • This equipment must not be operated or serviced unless the operator read the operating instructions and

fully understands the purpose, consequences and procedure of each step.• When operating a larger tool (TX-16, TX-32, or TX-45) above waist height, employ a secondary means of

support for safety purposes. A tool sling or chains may be used. Consult your safety department for further suggestions.

Depending on the working environment your local health and safety regulations may require you wear protective gear (i.e. safety shoes, hard hat, gloves, coveralls, etc.). In case external forces are exerted on the equipment, non-compliance with these regulations may result in injury. EAR PROTECTION MUST BE WORN WHEN OPERATING THIS TOOL.

The Torque Reaction Arm must be positioned against a positive stop. Do not use the arm as a dead handle. Take all precautions to make certain the operator’s hand cannot be pinched between the arm and a solid object.

Do not use damaged, frayed or deteriorated hydraulic hoses and fittings.

WARNING

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PLACING THE TOOL IN SERVICE

SETTING THE TORQUE

After determining the desired torque, use the torque conversion charts on pages 7 to 20 to determine the pressure that is necessary to achieve that torque.

1. Connect the tool to the power supply and turn the pump on.2. Depress the remote control button causing the pressure to be shown on the gauge.3. Adjust the pressure by loosening the wing nut that locks the pressure adjustment thumbscrew.

Rotate the thumbscrew clockwise to increase the pressure and counterclockwise to decrease the pressure. When decreasing pressure, always lower the pressure below the desired point and then bring the gauge back up to the desired pressure.

4. When the desired pressure is reached, retighten the wing nut and cycle the tool again to confirm that the desired pressure setting has been obtained.

OPERATING THE WRENCH

The position of the tool relative to the nut determines whether the action will tighten or loosen the nut. (Refer to Dwg. 2 for application examples). The power stroke of the piston assembly will always turn the ratchet hex toward the shroud.

1. Place the ratchet hex on the nut. Make certain it is the correct size for the nut and that it fully engages the nut.

2. Position the reaction surface against an adjacent nut, flange or solid system component. Make certain that there is clearance for the hoses, swivels, and inlets. DO NOT allow the tool to react against the hoses, swivels, or inlets.

Wrench Positions Dwg. 2

CONNECTING THE TOOL

1. Attach the twin line hose to the swivel inlets of the square drive torque wrench using the spring–loaded quick connect ends.

2. Connect the opposite ends of the hose to the pump in the same manner.

3. Push the link retaining pin out of the low profile drive cylinder.

4. Mate the selected ratchet link to the cylinder by inserting the end of the cylinder opposite the swivel inlets between the side plates of the ratchet link. (Refer to Dwg. 1)

5. Align the holes for the link retaining pin and insert the pin through the side plates and cylinder to keep the units joined together.

Dwg. 1

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PLACING THE TOOL IN SERVICE

3. After having turned the pump on and presetting the pressure for the correct torque, depress the remote control button to advance the piston assembly. If the notch in the piston rod did not engage the retract pin in the ratchet link when the link was joined to the housing, it will engage the pin automatically during the first advance stroke.

4. When the link is connected to the cylinder and the wrench is started, the reaction surface of the wrench will move against the contact point and the nut will begin to turn.

5. When the nut is no longer turning and the pump gauge reaches the preset pressure, release the remote control button. The piston rod will retract when the button is released. Under normal conditions, an audible “click” will be heard as the tool resets itself.

6. Continue to cycle the tool until it “stalls” and the preset psi/torque has been attained.7. Cycle the tool one last time to ensure full total torque.

MARINE MOLY GREASE

Lubrication frequency is dependent on factors known only to the user. The amount of contaminants in the work area is one factor. Tools used in a clean room environment will obviously require less service than a tool used outdoors and dropped in loose dirt or sand. Marine Moly Grease is formulated not to wash out of the tool in areas where lubrication is critical. Whenever lubrication is required, lubricate as follows:

1. Separate the low profile cylinder from the ratchet link if they are joined.2. After wiping off the old grease, apply a daub of Marine Moly Grease to the hooking notch on the

piston rod and wipe a film of Marine Moly Grease onto the sides and faces of the two sliders.3. Disassemble the ratchet link as instructed in the Maintenance Section and wash the components

in a suitable cleaning solution in a well ventilated area.4. Dry the components, then wipe a film of Marine Moly Grease onto the wear surface of both side

plate sleeves and the hubs of the ratchet.5. Spread a light film of Marine Moly Grease onto the inner faces of both side plates covering the

area where the drive plate and drive segment travel. DO NOT pack the teeth of the drive segment or ratchet with lube. It can prevent the teeth from engaging properly.

6. Reassemble the ratchet link as instructed in the Maintenance Section.

LUBRICATION

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TX Series Wrench Technical & Dimensional Data

Model Number TX-1 TX-2 TX-4 TX-8Min. Torque (ft/lbs) 45 192 395 830Max. Torque (ft/lbs) 560 1928 3950 8630Min. Torque (nm) 61 260 535 1125Max. Torque (nm) 759 2614 5355 11699Output Accuracy +/-3% +/-3% +/-3% +/-3%Repeatability 100% 100% 100% 100%Duty Cycle 100% 100% 100% 100%Cylinder Weight (lbs/kg) 1.0/0.5 3.5/1.6 6.0/2.7 11.7/5.0

Link Weight (lbs) 1.0-1.0 2.4-3.5 5.4-7.6 11.9-14.5(kg) 0.45-0.45 1.0-1.5 2.4-3.4 5.5-6.5

Length (in/mm) 4.37/111.0 6.45/163.8 7.87/199.9 10.18/258.6Width (in/mm) 0.78/19.8 1.25/31.8 1.63/41.4 2.05/52.1Radius (in/mm) 0.23/5.8 0.36/9.1 0.46/11.7 0.54/13.7Height (in/mm) 3.25/82.6 4.00/101.6 5.60/142.2 7.00/177.8Hex Range From 1/2”/13mm 3/4”/19mm 1”/27mm 1 7/8”/49mmHex Range To 2”/50mm 2 9/16”/65mm 3 1/8”/80mm 4 5/8”/120mm

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TX Series Wrench Technical & Dimensional Data

Model Number TX-16 TX-32 TX-45Min. Torque (ft/lbs) 1560 3220 4850Max. Torque (ft/lbs) 16600 35650 47380Min. Torque (nm) 2115 4365 6575Max. Torque (nm) 22503 48327 64239Output Accuracy +/-3% +/-3% +/-3%Repeatability 100% 100% 100%Duty Cycle 100% 100% 100%Cylinder Weight (lbs/kg) 16.0/7.3 26.0/11.5 29.0/13.0

Link Weight (lbs) 21.0-28.0 29.0-39.5 29.0-39.5(kg) 9.5-13.0 13.0-17.9 13.0-17.9

Length (in/mm) 12.93/328.4 15.80/401.3 16.75/425.5Width (in/mm) 2.50/63.5 3.24/82.3 4.88/124.0Radius (in/mm) 0.65/16.5 0.93/23.6 0.93/23.6Height (in/mm) 7.58/192.5 9.50/241.3 10.28/261.1Hex Range From 2 3/16”/55mm 3 1/8”/80mm 3 1/8”/80mmHex Range To 5 5/16”/135mm 7 7/8”/200mm 7 7/8”/200mm

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8

9

10

11

12

13

14

15

16

17

18

19

20

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TX-1 Series Cylinder

Part Numbers for OrderingITEM NAME PART # QTY.

1 Housing TX-1-C01 12A Piston Rod TX-1-C03-1 12B Piston Cap TX-1-C03-2 16 Slider TX-1-C09 27 End Cap TX-1-C11 19 Link Pin TX-1-C15 1

12 Plunger TX-1-C25 113 Plunger Spring TX-1-C26 114 Slider Pin TX-1-C27 115 Plunger Pin TX-1-C28 116 End Plug Seal TX-1-C29 117 Rod Seal TX-1-C31 119 Piston Seal TX-1-C33 120 Rod Bushing TX-1-C51 126 Whip Hose - 16” HPH-16”-1/8 228 Coupler Set HC-S-100 1

Piston Assembly (2A & 2B) TX-1-C03

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TX-1 Series Link


1 Side Plate - Left TX-1-L01- #* 12 Side Plate - Right TX-1-L02- #* 13 Drive Plate TX-1-L03- #* 14 Drive Pin TX-1-L05 15 Drive Pin Spring TX-1-L07 16 Ratchet TX-1-L09- #* 17 Drive Segment TX-1-L11- #* 111 Spacer Pin TX-1-L17 312 Sideplate Sleeves TX-1-L19- #* 214 Segment Spring TX-1-L25 115 Side Plate Screws TX-1-L29 316 Dr. Pin Spring Roll Pin TX-1-L33 1

*part number is dependent upon ratchet link size

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1 Housing TX-2-C01 12 Piston TX-2-C03 16 Slider TX-2-C09 27 End Cap TX-2-C11 18 Retaining Ring TX-2-C13 29 Link Pin TX-2-C15 1

10 End Cover TX-2-C17 111 End Cover Screw TX-2-C23 114 Slider Pin TX-2-C27 116 End Plug Seal TX-2-C29 117 Rod Seal TX-2-C31 119 Piston Seal TX-2-C33 121 Link Retaining Spring TX-2-C53 127 Swivel Assembly STX-8M-4M 228 Coupler Set HC-S-100 140 Seal Insertion Tool ATX-2-ST

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TX-2 Series Link


1 Side Plate - Left TX-2-L01- #* 12 Side Plate - Right TX-2-L02- #* 13 Drive Plate TX-2-L03- #* 14 Drive Pin TX-2-L05 15 Drive Pin Spring TX-2-L07 16 Ratchet TX-2-L09- #* 17 Drive Segment TX-2-L11- #* 18 Upper Spacer TX-2-L13- #* 1

10 Lower Spacer TX-2-L15- #* 111 Spacer Pin TX-2-L17 212 Sideplate Sleeve TX-2-L19- #* 213 Shroud TX-2-L21 114 Segment Spring TX-2-L25 115 Upper Spacer Screw TX-2-L27 416 Lower Spacer Screw TX-2-L29 417 Shroud Screw TX-2-L31 218 Dr. Pin Spring Roll Pin TX-2-L33 1


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10 End Cover TX-4-C17 111 End Cover Screw TX-4-C23 114 Slider Pin TX-4-C27 116 End Plug Seal TX-4-C29 117 Rod Seal TX-4-C31 119 Piston Seal TX-4-C33 120 Cylinder Gland TX-4-C51 121 Link Retaining Spring TX-4-C53 127 Swivel Assembly STX-4M-4M 228 Coupler Set HC-S-100 140 Seal Insertion Tool ATX-4-ST41 Gland Removal Tool ATX-4-GW

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TX-4 Series Link



10 Lower Spacer TX-4-L15- #* 111 Spacer Pin TX-4-L17 212 Sideplate Sleeve TX-4-L19- #* 213 Shroud TX-4-L21 114 Segment Spring TX-4-L25 115 Upper Spacer Screw TX-4-L27 416 Lower Spacer Screw TX-4-L29 417 Shroud Screw TX-4-L31 218 Dr. Pin Spring Roll Pin TX-4-L33 1


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10 End Cover TX-8-C17 111 End Cover Screw TX-8-C23 114 Slider Pin TX-8-C27 116 End Plug Seal TX-8-C29 117 Rod Seal TX-8-C31 119 Piston Seal TX-8-C33 120 Cylinder Gland TX-8-C51 121 Link Retaining Spring TX-8-C53 127 Swivel Assembly STX-4M-4M 228 Coupler Set HC-S-100 140 Seal Insertion Tool ATX-8-ST41 Gland Removal Tool ATX-8-GW

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TX-8 Series Link



10 Lower Spacer TX-8-L15- #* 111 Spacer Pin TX-8-L17 212 Sideplate Sleeve TX-8-L19- #* 213 Shroud TX-8-L21- #* 114 Segment Spring TX-8-L25 115 Upper Spacer Screw TX-8-L27 416 Lower Spacer Screw TX-8-L29 417 Shroud Screw TX-8-L31 218 Dr. Pin Spring Roll Pin TX-8-L33 1


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1 Housing TX-16-C01 12A Piston Rod TX-16-C03-1 12B Piston Cap TX-16-C03-2 13 Valve Ball TX-16-C03-3 14 Valve Spring TX-16-C03-4 15 Valve Cup TX-16-C03-5 16 Slider TX-16-C09 27 End Cap TX-16-C11 19 Link Pin TX-16-C15 1

14 Slider Pin TX-16-C27 116 End Plug Seal TX-16-C29 117 Rod Seal TX-16-C31 1

ITEM NAME PART # QTY.19 Piston Seal TX-16-C33 120 Cylinder Gland TX-16-C51 121 Link Retaining Spring TX-16-C53 122 Seal Plate TXU-16-C54 123 O-ring (Large) USL-11 124 O-ring (Small) USL-13 425 Seal Plate Screw USL-23 427 Swivel Assembly STX-4M-4M 228 Coupler Set HC-S-100 141 Gland Removal Tool ATX-16-GW

Piston Assembly (2A, 2B, 3, 4, 5) TX-16-C03

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TX-16 Series Link


1 Side Plate - Left TX-16-L01- #* 12 Side Plate - Right TX-16-L02- #* 13 Drive Plate TX-16-L03- #* 14 Drive Pin TX-16-L05 15 Drive Pin Spring TX-16-L07 16 Ratchet TX-16-L09- #* 17 Drive Segment TX-16-L11- #* 18 Upper Spacer TX-16-L13 19 Middle Spacer TX-16-L14- #* 110 Lower Spacer TX-16-L15- #* 111 Spacer Pin TX-16-L17 212 Sideplate Sleeve TX-16-L19- #* 213 Shroud TX-16-L21 114 Segment Spring TX-16-L25 115 Upper Spacer Screw TX-16-L27 416 Lower Spacer Screw TX-16-L29 417 Shroud Screw TX-16-L31 218 Dr. Pin Spring Roll Pin TX-16-L33 119 Spacer Roll Pin TX-16-L35 1


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14 Slider Pin TX-32-C27 116 End Plug Seal TX-32-C29 117 Rod Seal TX-32-C31 1

ITEM NAME PART # QTY.19 Piston Seal TX-32-C33 120 Cylinder Gland TX-32-C51 121 Link Retaining Spring TX-32-C53 122 Seal Plate TXU-32-C54 123 O-ring (Large) USL-11 124 O-ring (Small) USL-13 425 Seal Plate Screw USL-23 427 Swivel Assembly STX-4M-4M 228 Coupler Set HC-S-100 141 Gland Removal Tool ATX-32-GW


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TX-32/45 Series Link


1 Side Plate - Left TX-32-L01- #* 12 Side Plate - Right TX-32-L02- #* 13 Drive Plate TX-32-L03- #* 14 Drive Pin TX-32-L05 15 Drive Pin Spring TX-32-L07 16 Ratchet TX-32-L09- #* 17 Drive Segment TX-32-L11- #* 18 Upper Spacer TX-32-L13 19 Middle Spacer TX-32-L14- #* 1

10 Lower Spacer TX-32-L15- #* 111 Spacer Pin TX-32-L17 212 Sideplate Sleeve TX-32-L19- #* 213 Shroud TX-32-L21 114 Segment Spring TX-32-L25 115 Upper Spacer Screw TX-32-L27 416 Lower Spacer Screw TX-32-L29 417 Shroud Screw TX-32-L31 218 Dr. Pin Spring Roll Pin TX-32-L33 119 Spacer Roll Pin TX-32-L35 1


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14 Slider Pin TX-45-C27 116 End Plug Seal TX-45-C29 117 Rod Seal TX-45-C31 118 Piston Cup Seal TX-45-C32 119 Piston Seal TX-45-C33 120 Rod Bushing TX-45-C51 121 Link Retaining Spring TX-45-C53 127 Swivel Assembly STX-4M-4M 228 Coupler Set HC-S-100 141 Gland Removal Tool ATX-45-GW


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MAINTENANCE SECTION

Always turn off the power supply. Bleed off hydraulic fluid from the hose connections on the cylinder assembly and disconnect the hoses before attempting to repair or perform maintenance on this tool. Always wear eye protection when operating or performing maintenance on this tool.

DISASSEMBLYGENERAL INSTRUCTIONS

1. Do not disassemble the tool any further than necessary to replace or repair damaged parts.2. Use extra care not to score, nick or damage surfaces that will contain hydraulic oil under pressure.3. Whenever grasping a tool in a vise, always use leather–covered or copper–covered vise jaws to

protect the surface of the part and help prevent distortion. This is particularly true of threaded members and housings.

4. Do not remove any part that is press fit in or on an assembly unless the removal of that part is necessary for repairs or replacement.

5. Do not disassemble the hydraulic cylinder assembly unless you have a complete set of seals and O–rings for replacement.

6. Use only British Standard fractional size tools when disassembling these tools.

DISASSEMBLY OF THE TOOL

1. Push the link pin (9) out of the housing (1) and side plates (1 & 2).2. Lift the housing from between the side plates and separate the two units.

DISASSEMBLY OF THE TX-1 CYLINDER ASSEMBLIES 1. Clamp the housing in copper-covered or leather-covered vise jaws with the inlet end upward, using

a wrench, unscrew and remove the two whip hoses (26) with their attached couplers (28). 2. Remove the housing assembly from the vise jaws and turn over a container to catch any oil

remaining inside the cylinder.3. Re-clamp the housing in the vise with the inlet end upward.4. Using a wrench on the hex of the end plug wrench, unscrew and remove the end cap (7) with the

end plug seal (16). 5. Using a socket on the hex of the piston cap (2B), unscrew and remove the piston cap from the

piston rod (2A).6. Remove the housing from the vise and turn over a container to empty any remaining oil from the

housing.7. Re-clamp the housing in the vise and remove the piston rod (2A) from the housing. If necessary,

tap the threaded end of the piston rod with a brass tap being careful not to damage the threads.8. Press the brass bushing (20), from the piston rod end of the housing, out of the housing.9. To remove the sliders (6), position the slider pin (14) over a clearance opening in a soft block and

use a small drift to tap the pin out of the sliders and the piston rod.

WARNING

35

During removal and after the piston shaft is removed; DO NOT grasp the round portion of the shaft with any holding device that will damage the surface. Any nicks or scratches to the surface will allow hydraulic oil to leak from the cylinder when the tool is reassembled.

MAINTENANCE SECTIONDISASSEMBLY OF THE TX-2, TX-4, AND TX-8 CYLINDER ASSEMBLIES

1. Place the tool with the slider pin hole over a clearance opening and use a small drift to tap the slider pin (14) out of the sliders (6) and piston (2).

2. Clamp the housing in copper-covered or leather-covered vise jaws with the inlet end upward, using a 1/4” hex wrench, unscrew and remove the two swivel assemblies (27) with their attached couplers (28).

3. Remove the housing assembly from the vise jaws and turn over a container to catch any oil remaining inside the cylinder.

4. Re-clamp the housing in the vise with the inlet end upward.5. Use a hex wrench to unscrew and remove the end cover screw (11). Remove the end cover (10).6. Tap the end cap (7) inward approximately 1/2” and remove the two retaining rings (8) by working

them out of the groove in the cylinder. Note: Covering the oil ports with a cloth will contain any oil that may expel from the housing.

7. Install the seal insertion tool (40) on the inlet end of the housing. Note: Lubricating the inside of the insertion tool will ease in the removal of the piston (2) and end cap (7).

8. Invert the tool above the vice. Place a cloth draped between the jaws of the vice to contain the exiting parts. Spread the vice open enough to catch the end plug and piston.

9. Tap the piston with a brass tap lightly until both the piston and end cap slip through the housing and into the catch cloth.

10. Use the gland removal tool (41) to unscrew and remove the cylinder gland (20) from the housing. Note: The TX-2 does not have a cylinder gland.

DISASSEMBLY OF THE TX-16, TX-32 AND TX-45 CYLINDER ASSEMBLIES

1. Clamp the housing in copper-covered or leather-covered vise jaws with the inlet end upward, using a 1/4” hex wrench, unscrew and remove the two swivel assemblies (27) with their attached couplers (28).

2. Remove the housing assembly from the vise jaws and turn over a container to catch any oil remaining inside the cylinder.

3. Re-clamp the housing in the vise with the inlet end upward.4. Using a socket on the hex of the end cap (7), unscrew and remove the end cap with the end plug

seal. 5. Using a socket on the hex of the piston cap (2B), unscrew and remove the piston cap from the

piston rod (2A).6. Remove the housing from the vise and turn over a container to empty any remaining oil from the

housing.7. Re-clamp the housing with the end plug end upward in the vise. Place a cloth between the jaws of

the vice to contain the exiting parts. Gently tap the piston rod (2A) with a brass draft to remove it from the housing, being careful not to damage the threads.

The purpose of the seal insertion tool in the following step is to prevent the end plug seal from expanding into the retaining ring groove. If the tool is not used, place two thin pieces of flat stock at the midpoint of the opening against opposite walls to control the seal expansion.

CAUTION

NOTICE

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MAINTENANCE SECTION

TO REMOVE SEAL PLATE ON TX-16 AND TX-32

1. Unscrew seal plate screws. (25)2. Remove seal plate (22).3. Inspect o-rings (23 & 24), replace if needed.4. Insert seal plate into hole in housing.5. Use a thread locking compound on plate screws before fastening seal plate to housing.

DISASSEMBLY OF THE RATCHET LINK

1. Lay the ratchet link flat on a workbench with the left side plate (1) downward and using a hex wrench, unscrew and remove the two lower spacer screws (16). Note: TX-1 ratchet links do not have Upper Spacers or Lower Spacers.

2. Using a hex wrench, unscrew and remove the two upper spacer screws (15). Note: TX-1 ratchet links do not have Upper Spacers or Lower Spacers.

3. For series TX-16, TX-32, and TX-45 models: Use a roll pin punch to tap the spacer roll pin (19) out of the right side plate (2).

4. While applying thumb pressure to the edge of the ratchet (6), carefully lift the side plate off the assembly.

5. Grasp the ratchet and drive plate (3) and, while maintaining their relationship, lift them both off the left side plate.

6. Push the ratchet out of the drive plate and remove the drive segment (7) and the segment spring (14) from the drive plate recess.

7. If the drive pin (4) or drive pin spring (5) must be replaced, use a roll pin punch to push the drive pin spring roll pin (18) out of the drive plate. Once the pin spring is removed, the drive pin (4) will drop down to the large opening at the bottom of the slot for easy removal.

8. Lift the lower spacer (10) off the lower spacer pins (11). If the pins must be replaced, use a hex wrench to remove the two lower spacer screws from the right side plate. Pull the pins out of the holes on the inner face of the right side plate.

9. For Series TX-2, TX-4, and TX-8 models: Unscrew the two spacer screws and remove the upper spacer (8) from the right side plate. For Series TX-16, TX-32, TX-45 models: Use a roll pin punch to remove the spacer roll pin (19) from the right side plate. Unscrew the two spacer screws and remove the middle spacer (9) and upper spacer (8) from the right side plate.

10. If the side plate sleeves (12) must be replaced, press the sleeves out toward the inner face of the side plate. Note: TX-1 ratchet links do not have Upper Spacers or Lower Spacers.

Under normal circumstances, the seal plate will not need to be removed for maintenance.

When the ratchet is removed from the drive plate, the drive segment and segment spring will be free to fall from the drive plate recess. Do not allow the drive segment to fall on a hard surface that might chip the teeth.

8. Reclamp the housing in the vice so that the cylinder gland (20) is visible.9. Use the gland removal tool (41) to unscrew the cylinder gland (20) from the housing. 10. Place the slider pin in the piston rod over a clearance opening in a soft block. Use a small drift to

tap the pin out of the sliders and piston rod.

NOTICE

NOTICE

37

MAINTENANCE SECTION

ASSEMBLY

ASSEMBLY OF TX-1 CYLINDER ASSEMBLIES

1. Press the slider pin (14) into one of the sliders (6) until flush with one side. Install the pin through the hole in the piston rod (2A) and press the remaining slider into the pin.

2. With the inlet end of the housing upward, press the brass bushing (20), with the shoulder trailing, into the housing.

3. Clamp the housing in copper-covered or leather-covered vise jaws with the inlet end downward.4. Insert the piston rod (2A), threaded end leading, into the small central opening in the housing. The

notch in the trailing end of the rod should be towards the retaining pin hub.5. Reclamp the housing in the vise with the inlet end upwards. 6. Insert the piston cap (2B), hex end trailing, into the bore of the housing and use a socket to thread

and tighten the piston cap onto the piston rod.7. Thread the end cap (7), O-ring leading, into the bore of the housing and tighten. 8. Wrap the threads of the whip hoses (26) with Teflon tape.9. Install the male coupler hose into the end cap port and the female coupler hose into the housing

port ASSEMBLY OF TX-2, TX-4, AND TX-8 CYLINDER ASSEMBLIES

1. Clamp the housing (1) in copper-covered or leather-covered vise jaws with the inlet end downward.2. Apply a non-permanent thread-locking compound to the threads of the cylinder gland (20). Use

the gland removal tool (41) to thread the bushing into the small central opening in the housing and tighten until flush with the housing (1). Note: TX-2 does not have a cylinder gland.

3. Flip the housing (1) in the vise and install the seal insertion tool (40). Note: Lubricating the inside of the insertion tool and the sides of the piston rod assembly and end cap will ease installation.

4. Insert the piston (2) into the seal insertion tool (41), notched end leading and toward the link pin hub, and tap into housing approximately 1”.

5. Insert the end cap (7), swivel inlet toward the link pin hub, into the seal insertion tool (40), and tap in until the piston (2) bottoms out against the housing (1).

6. Install retaining rings (8), tapered edge leading into the grooves in the housing.7. Flip the housing in the vise and drive the piston (2) into the housing with a brass tap until the end

cap (7) seats in the retaining rings (8).8. Install the end cover (10), applying a non-permanent thread-locking compound to the end cover

screw (11) threads.9. Remove the housing from the vice and place on a soft block with the engraved side up.10. Install sliders (6), one on each side of piston (2). For TX-8 models: Install sliders with the cutout

towards the piston. Align the holes in the sliders with the holes in the piston and the housing.11. Install slider pin (14) until flush with top slider.12. Apply moly grease to the face of the sliders and the notch in the piston.13. Wrap the threads of the swivel assemblies (27) with Teflon tape.14. Install the male coupler swivel into the end cap port and the female coupler swivel into the housing.

Inspect all parts prior to assembly. Replace any worn or damaged parts.NOTICE

38

ASSEMBLY OF TX-16, TX-32 AND TX-45 CYLINDER ASSEMBLIES

1. Press the slider pin (14) into one of the sliders (6) until flush with one side. Install the pin through the hole in the piston rod (2A) and press the remaining slider into the pin.

2. Clamp the housing in copper-covered or leather-covered vise jaws with the inlet end downward.3. Apply a non-permanent thread-locking compound to the threads of the cylinder gland (20). Use the

gland removal tool (41) to thread the gland into the small central opening in the housing and tighten until flush with the housing (1).

4. Insert the piston rod (2A), threaded end leading, into the small cylinder gland in the housing. The notch in the trailing end of the rod should be towards the retaining pin lug.

5. Reclamp the housing so that the inlet end is upwards.6. Insert the piston cap (2B), hex end trailing, into the bore of the housing and use a socket to thread

and tighten the piston cap onto the piston rod.7. Thread the end cap (7), O-ring leading, into the bore of the housing and tighten with a socket.8. Wrap the threads of the swivel assemblies (27) with Teflon tape.9. Install the male coupler swivel into the end cap port and the female coupler into the housing port.

MAINTENANCE SECTION

Inspect all parts prior to assembly. Replace any worn or damaged parts.

ASSEMBLY OF THE RATCHET LINK

1. If the side plate sleeves (12) were removed, press new sleeves, shoulder end trailing, into the right and left side plates (1 & 2) from the inner face of the side plates. Make certain the sleeves are square with the side plate faces and that the shoulder of the sleeves enters the recesses in the side plates and are pressed flush with the faces.

2. For Series TX-2, TX-4, and TX-8 models: Position the upper spacer (8) against the inside face of the right side plate. Apply a non-permanent thread-locking compound to the threads of the two upper spacer screws (15) and secure the spacer with the screws through the side plate. For Series TX-16, TX-32, TX-45 models: Press the spacer roll pin (19) into the right side plate with one end of the pin flush with the external face of the side plate. Insert the tab of the upper spacer (8) into the slot in the middle spacer (9). After aligning the holes in both pieces, install them on the spacer roll pin (19). When they are correctly positioned, apply a non-permanent thread-locking compound to the threads of the two upper spacer screws (15) and secure the spacers with the screws through the side plate.

3. Insert the two lower spacer pins (11) into the holes in the lower edge of the right side plate. Apply a non-permanent thread-locking compound to the threads of the lower spacer screws (16) and secure the pins with the screws through the side plate. Note: The TX-1 ratchet links do not have Upper Spacers and Lower Spacers.

4. Place the lower spacer (10) over the pins against the side plate. Make certain it is correctly oriented so that no part of the spacer extends beyond the edge of the side plate. Note: The TX-1 ratchet links do not have Upper Spacers and Lower Spacers.

5. Insert the drive pin (4) into the small cross-hole and slot in the drive plate (3). Invert the plate causing the ends of the pin to enter the slot and move the pin to the narrow end.

6. Position the drive pin spring (5) in the drive plate slot with the two non-connected ends between the drive pin and the large hole in the slot. Position the closed end of the spring on the opposite side of the pin and then apply pressure on the spring to align the hole through it with the hole in the drive plate for the drive pin spring roll pin (18). Insert the spring roll pin into the drive plate, through the spring and into the far wall of the drive plate.

NOTICE

39

MAINTENANCE SECTION

In the following step, an excessive amount of grease will prevent proper tooth engagement between the ratchet and the drive

segment, causing the tool to malfunction.

7. Wipe a thin film of Marine Moly Grease onto the inner face of the large opening in the drive plate.8. Position the ratchet (6) in the central opening of the drive plate.9. Insert the drive segment (7) into the opening adjacent to the ratchet. Make certain the teeth of

the ratchet correctly engage the teeth of the drive segment. Reverse the ratchet if they do not properly engage.

10. Slide the drive segment sideways to expose the spring hole. Install the segment spring (14) into the hole. While compressing the spring, slide the drive segment inward until the drive plate captures the segment spring.

11. Apply a light coat of Marine Moly Grease to both sides of the drive plate and drive segment as well as the inner races of both side plate sleeves (12).

12. While keeping the assembly together, insert the hub of the ratchet into the side plate sleeve of the assembled side plate.

13. Place the left side plate sleeve on the hub of the ratchet and align the screw holes for the spacers.14. After applying a non-permanent thread-locking compound to the threads and using hex wrenches,

install the two remaining lower spacer screws.ASSEMBLY OF THE TOOL

1. With the cylinder assembly in one hand and the ratchet link in the other, hook the notch on the shaft of the piston rod (2A) onto the drive pin (4) and bring the two assemblies together.

2. Insert the link pin (9) into the hole in the side plate (1 or 2) until the link pin snaps into the link retaining spring (21).

NOTICE

40

TROUBLESHOOTING GUIDE

Trouble Probable Cause Solution

Piston will not advanceor retract

Couplers are not securely attached to the tool or pump

Check the coupler connections and make certain that they are connected.

Coupler is defective Replace any defective coupler.

Defective remote control switch Replace the switch and/or controlpendent.

Dirt in the direction-control valve of the pump unit

Disassemble the pump and clean the direction-control valve.

Piston will not retract

Hose connections reversed

Make certain the advance on the pump is connected to the advance on the tool and retract on the pump is connected to

the retract on the tool.

Retract hose not connected Connect the retract hose securely.

Retract pin and/or spring broken Replace the broken pin and/or spring.

Cylinder will not build up pressure

Piston seal and/or end plug seal leaking Replace any defective o-rings.

Retaining screws sheared Replace any broken screws.Coupler is defective Replace any defective coupler.

Ratchet will not turn

Grease or dirt build up in the teeth of the ratchet link

and drive segment

Disassemble the ratchet and clean the grease or dirt out of the teeth.

Worn or broken teeth on ratchet and/or drive segment Replace any worn or damaged parts.

Tool tightens immedi-ately when turned on Hose connections are reversed

Depress the advance button to release the tool; shut the pump off in the

advance position and reverse the hose connection.

Pump will not build up pressure

Defective relief valve Inspect, adjust or replace the relief valve.

Air supply too low or air hose too small

Make certain the air supply and hose size comply with the pump manual

recommendations.

Electric power source is too lowMake certain the amperage, voltage and any extension cord size comply with the pump manual requirements.

Defective gauge Replace the gauge.

Low oil level Check and fill the pump reservoir.

Clogged filter Inspect, clean and/or replace the pump filter.

Pressure reading erratic Defective gauge Replace the gauge.

SAVE THESE INSTRUCTIONS DO NOT DESTROY

NOTES:

Phone: +1 610-250-5800 Fax:+1 610-250-2700

Toll Free: 1-888-TORCUP-1Email: [email protected] Website: www.torcup.com

1025 Conroy Place, Easton, PA. 18040 U.S.A.

MANUAL - TorcUP · 2018. 5. 25. · 1. OPERATION AND MAINTENANCE. MODELS TX-1, TX-2, TX-4, TX-8, TX-16, TX-32, TX-45. MANUAL. TX Series Low Profile Hydraulic Torque Wrenches. TX Series.

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